NEXON NEW MCE-2 DCT BS VI DTC Troubleshooting Guide Version: 1.0 Date: 16-06-2023 Author: Akash/Rahul Page:479 of 645 Copyright ©TATA MOTORS Ltd. This document must not be used in any way, such as copying and redistributing to third parties, without the consent of author. 135. P3120-00 Gear actuation failure on synchronizer engagement Overview: ISO Code P3120-00 Customer Symptom • Warning message; 'get vehicle checked" • Transmission Fault Lamp ON Fault Effects (On Vehicle) • Warning message; 'get vehicle checked" • Transmission Fault Lamp ON Lamp Status (If Any) Transmission Fault Lamp ON (Service indication 0x2) Fault Detection Condition Failed to engage same synchronizer 3 times (FFT = 100ms) Normal Operating Condition TCU does not detect any fault Probable Trouble Area 1. Clutch cooling valve. 2. BLDC motor (coil resistance U-V / V-W / W-U = 46,6 mOhm, if value is deviating > 5 mOhm = NOK). 3. TCU. 4. BLDC motor. 5. Transmission. Healing Condition The reaction is cleared at SW restart if the detection is FALSE for more than 0 ms Component Details: Gear actuation failure on synchronizer engagement due to clutch cooling valve, HCU,BLDC motor issue. Preliminary Checks: 1) Loose/ Damaged Connections between Electro valve and TCU. 2) Loose/ Damaged mechanical fitments of TCU (TCU to valve body mounting). 3) Check correct fitment of ground cable connections on vehicle chassis. Trouble Shooting:- Step Checks IF YES IF NO 1 Check if fault codes on clutch cooling valve are active, bad clutch actuation can cause gear actuation problems. solve clutch problems (HCU replacement), Clear the DTC and check if the DTC does not come back. Go to step 2 2 If DTC persists, Check BLDC motor (coil resistance U-V / V-W / W-U = 46,6 mOhm, if value is deviating > 5 mOhm = NOK), If NOK, replace the BLDC motor. Clear the DTC and check if the DTC does not come back. Go to step 3 3 If DTC persists, Check with different TCU (flash the adaption data from the original TCU) if the problem persists, if NOK, Replace TCU. Clear the DTC and check if the DTC does not come back. Go to step 4 4 If DTC persists , Replace BLDC motor, even if coil resistance is ok Clear the DTC and check if the DTC does not come back. Go to step 5 5 If DTC persists, verifiy synchronizer wear , if confirmed ; transmission replacement Clear the DTC and check if the DTC does not come back. • Resistance Check
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